Rotating bucket for product handling apparatus

ABSTRACT

Improved product handling and transfer apparatus includes rotatable product buckets for receiving product and re-orienting product for packaging in diverse configurations or containers. Buckets preferably include channels spanned by deposited product or receiving product therein, with bucket turning as appropriate to a packaging configuration. Flat bottom buckets and methods are disclosed.

RELATED APPLICATIONS

This application is a divisional of U.S. Ser. No. 12/567,015, filed Sep.25, 2009, now allowed on Mar. 28, 2013 and will issue on Jul. 22, 2014as U.S. Pat. No. 8,783,000. Priority of said application U.S. Ser. No.12/567,015, filed Sep. 25, 2009 is claimed as well as priority of U.S.Provisional application Ser. No. 61/194,285, filed Sep. 26, 2008, whichis claimed. Both said applications are herewith incorporated byreference.

FIELD OF THE INVENTION

This invention relates to transferring, conveying or handling items andmore particularly to a product conveyor.

BACKGROUND OF THE INVENTION

It has been known to rotate products in a process or packaging line byrotating the product carried by a conveyor. The following disclosuresillustrate such prior systems: U.S. Pat. Nos. 6,202,392; 6,435,332;6,698,163 and EP 1 801 014 A1, copies of which are attached and each ofwhich is incorporated herein by reference. As one example of a producthandling device, products are turned relative to and while on asupporting device like a product bucket. In such an exemplary device,facial tissues are produced in select count stacks or clips comprisingone flat tissue lying atop another in an elongated flat shaped stackbeing generally longer than it is wide. Such clips are then packaged invarious cartons and supplied to consumers.

There are two primary designs for tissue packaging generally used in theindustry. One type of carton is referred to as “flats” and is generallyrectangular. For flat cartons, the clip is simply pushed endwise from acartoner bucket into the box. Typically, the box has at least one majorpanel generally parallel with the tissues and an opening in the panelprovides access for tissue removal for use. Another type of carton isreferred to as “cubes” or “boutiques” and is more square or boxlike thanthe rectangular cartons of flats. This type of carton is more confiningand the clips must be bent into a U-shape and, thusly configured, pushedsideways into the boutique carton. In a similar manner, a major paneladjacent the bend in the confined clip is provided with an opening foraccessing the tissues for withdrawal and use.

To provide packaging in both a flat carton and a boutique carton,manufacturers typically have two options. One option is for themanufacturer to have two cartoning machines wherein one would handle aflat carton and the other would handle a boutique carton. This approach,however, involves the additional cost of an extra machine. A secondoption is to use a single machine capable of packaging one type ofcarton and being further capable of packaging the second type of cartonupon reconfiguration. In this case, the machine would be stopped andmany changeover parts added/removed to reconfigure the machine to renderit operable for properly configuring the clip for the new carton. Such aprocess, however, results in production downtime and significant expensefor changeover parts.

More recently, there have been some devices capable of packaging tissuein either a flat carton or boutique carton in an improved manner withoutextensive downtime and with a fewer number of changeover parts. One suchdevice and system is described in U.S. Pat. No. 6,202,392 (the '392patent), which patent is expressly incorporated herein by reference asif fully expressly reproduced herein. In that device, a tissue handlingapparatus includes a bucket conveyor having a plurality of bucketswherein each bucket includes a floor having a transverse or laterallyextending or directed channel. The buckets are oriented such that thetransverse channel extends substantially perpendicular to the machinedirection of the buckets along the bucket conveyor. All clips ofwhatever final configuration are fed into the buckets with theirelongated length oriented in a downstream direction parallel to themachine direction of the buckets so that the longer clips span over thenarrower transverse channel in their respective buckets.

When it is desired to fill a boutique carton, the clip is maintained inits original position spanning the channel, its length being longer thanthe channel is wide. A tamp or confiner is moved in over the clip andpushes an intermediate portion of the clip down into the channel into aU-shaped configuration with a central portion of the clip at leastpartially down in the channel and the outer ends contacted by the bucketfloor or the channel walls and being directed upwardly. From thisposition, the U-shaped clip may now be pushed transversely and sidewaysout of the bucket and into a boutique carton. When it is desired to fillflat cartons, however, the clip is turned on and with respect to thebucket so that it extends across the bucket and parallel to thetransverse channel. This turning causes the flat clip to fall into thetransverse channel. From there, it can then be pushed transversely andendwise into a flat carton.

In order to turn and drop the clip and maintain it in appropriatealignment at the same time, the handling apparatus includes two offsetopposed pushers engaging side edges of the flat clip at offsetlongitudinal positions to carefully turn the clip and allow the clip todrop into the channel. In essence, with the bucket remainingrotationally stationary, the pushers rotate the clip relative to thebucket to position the clip in the transverse channel. The pushers maycomprise plates extendable transversely into the buckets from oppositesides and into and above the transverse channels. Ends of the pushersengage and twist or turn the clip. Once in alignment with the channel,the clips are aligned with internal facing sides of the pushers whichconfigure and guide the clip through its fall into the channel.

Thereafter, the pushers are retracted and the clips are conveyeddownstream to a cartoner where they can be pushed endwise transverselyacross the buckets along the channels and into a flat carton. Thepushers are carried on a barrel loader-like apparatus disposed onopposite sides of the bucket conveyor and are either stopped or disabledwhen it is desired to configure the clips for loading boutique cartonswhere the clips are not turned. No change parts are required forselectively turning or not turning the clips.

In another form of a prior approach to tissue clip handling, a productsupport has a flat bottom. The tissue clips resting on that surface areturned on that surface and relative to that surface. Such a device isshown in EP 1 801 014 A1, incorporated herein.

Manufacturers continually strive to improve the packaging process,making the packaging of tissue and other items more efficient and costeffective. For example, the device described in the '392 patent includesa relatively large number of parts dedicated to turning the clipsrelative to the buckets when packaging flats. These parts requireregular maintenance and/or replacement. That device further includes anincreased length of the bucket conveyor so as to accommodate the pushersand turning of the clips in their respective buckets along the conveyor.This in turn leads to an increased number of buckets, an overall largermachine footprint and associated costs. The relatively larger machinefootprint may present challenges due to space constraints and maymandate a more complex line layout, which further increases costs.

Moreover, in the device of EP 1801014 A1, there is no provision forselective orientation of tissue clips in different packagingconfigurations.

Accordingly, it has been one objective of the invention to provide asingle, improved product handling apparatus and methods for selectivelyturning products and presenting them in different orientations as theymove through a processing or packaging line.

It has been a further objective of the invention to provide improvedapparatus and methods for transferring products such as tissue clips forproper orientation for insertion into flat cartons and for selectivetransferring of tissue clips for loading into boutique cartons.

It has been a further objective of the invention to provide improvedapparatus and methods for handling differently configured products onthe same handling apparatus having a reduced number of parts andaccommodating varied orientation of the products with a reduced machinefootprint.

SUMMARY OF THE INVENTION

To these ends, one embodiment of the invention contemplates a tissuehandling apparatus and methods wherein the buckets carried by a bucketconveyor are selectively rotatable relative to the bucket conveyor,depending on the type and orientation of product being handling orcarton being filled. The buckets of this embodiment have a similarconstruction as that described in the '392 patent and in one embodimentinclude a floor and a transverse channel disposed in the floor. However,unlike the buckets of the '392 patents, buckets described herein arerotatable to provide a variety of operational functions. According tothis embodiment, all clips of whatever final configuration they mayassume, are to the rotatable buckets with their elongated lengthpreferably oriented in a downstream direction parallel to the machinedirection of the buckets moving along the bucket conveyor. The bucketsmay be selectively rotatable so as to receive then orient thetransferred clips in an orientation appropriate for the type of cartonbeing filled.

The buckets have a first, default orientation or position as thatdescribed in the '392 patent, i.e., wherein the elongated transversechannel extends in a direction substantially perpendicular to themachine direction of the buckets. In the first position, the buckets areoriented for transferring for receiving and packaging clips in aboutique carton. To this end, the tissue clips are placed in the bucketsso as to span over the transverse channel in their respective buckets. Atamp or confiner is moved in over the clip and pushes an intermediateportion of the clip down into the channel into a U-shaped configuration.The U-shaped clip is then pushed transversely and sideways out of thebucket and into a boutique carton. In this way, the handling apparatusof the present invention operates in a manner similar to that describedin the '392 patent for the packaging of tissue clips in boutiquecartons.

In an advantageous aspect of the invention, the buckets are selectivelyrotatable to a second orientation or position wherein the elongatedtransverse channel extends substantially parallel to the machinedirection of the buckets moving along the bucket conveyor. The abilityto rotate the buckets between the first and second positions facilitatespackaging clips in a flat carton. To this end, the buckets may berotated away from the first position and to the second position prior toreceiving the clips therein. With the buckets in the second position,the transverse channel now extends substantially parallel to the machinedirection and the clips are fed or placed directly within the transversechannel. Once the clips are deposited within the transverse channel, thebuckets may be rotated from the second position back to the firstposition, i.e., with the transverse channel substantially perpendicularto the machine direction. As explained in the '392 patent, with thebuckets in the first position and the tissue clips properly positionedwithin the transverse channel, the clips may be pushed endwise into aflat carton. The buckets may be rotated from the first position back tothe second position prior to receiving another clip.

This embodiment of the invention effectively eliminates the pushers andother mechanisms that turn the tissue clips relative to the buckets soas to deposit the clips in the transverse channel when packaging flats.In this embodiment, the buckets rotate to a second position relative tothe bucket conveyor and the bucket supports so as to directly receivethe clips in the transverse channel, and then rotate back again to thefirst position to be in the proper orientation to push the clips intothe flat cartons. Because the turning of the clips is accomplished byturning the buckets relative to the bucket conveyor instead of turningthe clips relative to the buckets, as in the '392 patent, many of theparts dedicated to turning the clips in the device of the '392 patentmay be effectively eliminated. This reduces the costs associated withmaintaining those aspects of the device. Moreover, eliminating the partsthat turn the clips further reduce the length of the bucket conveyor,reduce the number of buckets on the bucket conveyor and reduce theoverall machine footprint.

Accordingly, the embodiment of the invention provides a flexible, dualfunction improved tissue handling apparatus for easily configuringtissue clips for flat or boutique cartoning.

In another embodiment of this invention, the product buckets have arelatively flat floor or product supporting surface. In other respects,the buckets and the structure facilitating their rotation are the sameas in the first embodiment described above. For boutique packaging,intermediate guides alongside the bucket conveyor may be used toconfigure the side-pushed clips for their boutique packages.

Accordingly, products including tissue clips as described above, or avariety of other products, are deposited on the flat bucket floor andthe buckets are pre-turned or are later rotated to achieve the proper ordesired product orientation for further processing, packaging or thelike.

It will be appreciated that this embodiment includes a rotating bucketnot limited to a bucket with a transverse channel in its floor, foreither tissue clip handling and packaging or for a wide variety of otherforms and applications or products where product rotation is desired.Such second embodiment thus provides both for tissue clip and otherproduct handling similar advantages as in the embodiment first describedabove.

These and other objectives and results will be readily appreciated bythose of ordinary skill in the art from the following detaileddescription of a preferred embodiment of the invention and from thedrawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute apart of this specification, illustrate embodiments of the invention and,together with a general description of the invention given above, andthe detailed description given below, serve to explain the invention.

FIG. 1 is a perspective view of a tissue handling apparatus inaccordance with the invention;

FIG. 2 is a perspective disassembled view of a rotatable bucket inaccordance with the invention;

FIG. 3 is a bottom plan view of an assembled rotatable bucket;

FIG. 4 is a side elevation view of the bucket shown in FIG. 3;

FIG. 5 is a top plan view of the bucket shown in FIG. 3;

FIG. 5A is a perspective sectional bottom view of a portion of thebucket turning apparatus of the invention in FIGS. 2-5;

FIG. 6 is a top plan view of the tissue handling apparatus shown in FIG.1;

FIG. 7 is a side elevation view of the tissue handling apparatus shownin FIG. 1;

FIG. 8A is a perspective view of the bucket orientation when it receivestissue clips for packaging in boutique cartons;

FIG. 8B is a perspective view of the bucket orientation when it receivestissue clips for packaging in flat cartons;

FIG. 9. is a perspective view of a second embodiment of the inventionincluding a bucket having a flat bottom;

FIG. 10 is an exploded view of the embodiment of FIG. 9;

FIG. 11 is a bottom plan view of the embodiment of FIGS. 9 and 10;

FIG. 12 is a side elevational view of the embodiment of FIGS. 9-11;

FIG. 13 is a top plan view of the embodiment of FIGS. 9-12;

FIG. 14 is a cross-sectional view taken along line 14-14 of FIG. 13 ofthe embodiment of FIGS. 9-13;

FIG. 15 is a detailed cross-sectional view of the encircled area of FIG.14; and

FIG. 15A is a perspective sectional bottom view of the embodiment inFIGS. 14, 15.

DETAILED DESCRIPTION

The present invention is an improvement and alternative to the tissuehandling apparatus described in the '392 patent, which patent isexpressly incorporated herein by reference as if fully expresslyreproduced herein. While this invention has multiple applications, oneparticular application is in a flat/boutique tissue clip transfer andpackage operation similar to that described in U.S. Pat. No. 6,202,392('392) and reference to that disclosure is made herein for environmentof use hereof. That patent discloses a tissue handling apparatus capableof selectively rotating a clip relative to the bucket to position theclip in a transverse channel for packaging in a flat carton. For aboutique carton, the clip does not require rotation. The presentapplication discloses in one embodiment an alternate manner in which torotate the clip for packaging the clip in a flat carton. In particular,instead of rotating the clip relative to the bucket when desiring topackage a clip in a flat carton, the entire bucket is rotated relativeto the bucket conveyor to orient the bucket to receive the clip androtated again to orient the bucket so as to push the clip into the box.

As many of the figures shown in the '392 patent show features that alsoapply to the handling apparatus of the present invention, thisspecification makes reference to some of those figures to explainbackground of the present invention. FIGS. 1 and 2 of the '392 patentillustrate the orientation of the clips of facial tissue both in arespective boutique clip configuration and in a flat clip configuration.In the tissue handling apparatus of the invention, this aspect has notchanged and that description also describes the orientation of the clipsin the present invention. Thus as shown in FIG. 1 of the '392 patent, anupright cubic or boutique carton has a tissue opening in a major panelwhich is situated on the bottom of the carton as shown in that figure. Aboutique clip is illustrated in its boutique configuration such that theclip itself takes on a bent or U-shaped configuration for loading intothe carton.

It will be appreciated that the clip has a width and a foreshortenedlength from end-to-end due to the bending of the tissues in the clip,but generally running from the narrow edge of one tissue through theclip to its narrow opposed and parallel edge. Such a clip is insertedinto the carton by means of a longitudinal U-shaped pusher moving in aload direction through an inclined guide bracket as is described in the'392 patent. The clips are preferably loaded on the move while they arebeing transported in a downstream or machine direction (MD) with thecartons and the pusher moving in the same downstream direction at thesame time such that the pusher is also moving transversely in the loaddirection to push the clips into the carton.

A carton of flat shape or configuration is shown in FIG. 2 of the '392patent. The carton is also provided with a tissue opening disposed in amajor bottom panel of the carton. A flat clip comprising a plurality offacial tissues has narrow ends, each defining across them a width, andthe clip is elongated between the ends, defining a length. A U-shapedpusher is moved in a load direction to push the flat clip endwise andtransversely into the carton. This is accomplished while the clip, thecarton and the pusher are also moving in a downstream direction.

It will be appreciated, as shown in FIGS. 1 and 2 of the '392 patentthat the cartons are conveyed in a downstream direction by a cartonconveyor, such as a lug type conveyor, while the pushers are conveyedsequentially in a downstream direction, one after the other, by means ofa well known barrel loader which is useful to convey the pushers in adownstream or machine direction while, at the same time, causing thepushers to extend transversely to load the clips into the cartonsrespectively.

At the same time, the clips are carried in the separate buckets of abucket conveyor in the machine direction. As will be described, theclips are pushed from these buckets transversely through transfer guidebuckets and into the cartons.

For illustration purposes, a complete system for loading individualclips which are discharged in any conventional manner, such as from alog saw, is illustrated in FIG. 3 of the '392 patent. A similar systemmay be used for loading individual clips in the present invention. Anymodifications of the system shown in FIG. 3 of the '392 patent in regardto the present invention will be appropriately noted. The system shownin FIG. 3 of the '392 patent includes a log saw discharging clips onto aclip conveyor from where the clips are introduced into a spacingapparatus including a turnwheel having depending clip pushing pins forengaging the rear end of the clips and moving the clips in a curvedpath, as shown in this embodiment as a 90 degree turn, into a cliphandling apparatus. While the length of the line in previous systemsoften mandated a line layout having a turn, and thus a turnwheel, in thepresent invention, it is contemplated that the turnwheel may becompletely eliminated and the clips on the clip conveyor may be feddirectly into the clip handling apparatus of the invention without sucha turn. Those of ordinary skill in the art should appreciate, however,that the clip handling apparatus of the invention may be used with sucha turnwheel. When there is no turnwheel, those of ordinary skill in theart should also appreciate that a smart belt system, as is known in theart, may be used to time the clips on the clip conveyor with the bucketson the bucket conveyor. Also, clips can be fed end-wise to the bucketsherein, but in a transverse direction perpendicular to the machinedirection of the bucket conveyor, with appropriate bucket rotationdepending on the desired transfer orientation of the clip.

When the clips are discharged from the wheel, they are deposited intobuckets on a bucket conveyor. The clips can be deposited on the bucketconveyor in any further known fashion and by any apparatus which doesnot comprise a part of this particular invention. The clips may be fedonto the ends of the buckets or pushed onto them in that manner, or maybe fed from an overhead position and dropped into the buckets. In anyevent, it will be appreciated that, at this point, all of the clips,whether to be formed in a boutique configuration or in a flatconfiguration are, in fact, flat and elongated in these and other feedconfigurations, in a machine direction as they reside on the buckets ofthe bucket conveyor at this position.

The clips are conveyed in the buckets to a cartoning apparatus formoving the clips from the full bucket conveyors into respective cartons.This cartoner includes carton feeding and erecting apparatus, a cartonconveyor, a transfer guide bucket conveyor and downstream cartonhandling apparatus including dust flap closing, gluing, flap closing,compression and other conveying apparatus for finishing the carton andfeeding it to a product discharge end of the cartoner, where therespective cartons either of the boutique style or the flat style aredischarged for packaging and shipment. The cartoner includes a barrelloader of typical configuration including a cam track for moving pushersto load cartons as will be described. Also, at the cartoner, a carouselis disposed above the bucket conveyor and transfer guide conveyor as isdescribed in the '392 patent.

The handling apparatus in the '392 patent is configured to selectivelyrotate the clips if packaging in a flat carton is desired. As shown inFIG. 4 of the '392 patent, the rotation of the clips is accomplishedwith a pair of offset pushers that engage the edges of the clip torotate the clip relative to the bucket so as to position the clip withina transverse channel in the bucket. That handling apparatus in the '392patent is replaced with the handling apparatus 10 best seen in FIG. 1 ofthe present application.

Turning now to FIG. 1 herein, it will be appreciated that a plurality ofclips is sequentially transported by a bucket conveyor 12 having aplurality of buckets 14 (one shown in FIG. 1). While the description ofthe invention refers to a specific embodiment of buckets 14 forreceiving the tissue clips, those of ordinary skill in the art willrecognize that the buckets may be configured as other frame members,positioning rails or other mechanical forms adapted to receive thetissue clips. At this point, it will be instructive to note that uponentering handling apparatus 10, the clips C are all preferably elongatedand in a flat configuration, having a longitudinal dimension moving inthe same direction and in parallel with the machine direction MD of thebucket conveyor 12.

Turning now momentarily to FIGS. 2-5 of the present application, oneembodiment of the individual buckets 14 of the bucket conveyor 12 willbe described. The configuration of the individual buckets 14 aresomewhat similar to that disclosed in the '392 patent in that theyinclude a bucket portion or product receiving member 15 having a bucketfloor comprising a rearward transverse floor surface 16 and a forwardtransverse floor surface 18 in a common horizontal plane. A transversechannel 20 is disposed in the floor defined by surfaces 16, 18 andcomprises channel walls 22, 24 and channel floor 26. Channel floor 26 isdepressed or lower than the floor surfaces 16, 18 of the productreceiving member bucket portion 15. Each bucket 14 is provided with aclip pusher 28 extending above the floor surface 16 at the trailing edgeof the bucket 14.

The buckets 14, however, further include a bucket member support 30mounted on two carrying brackets 32, 34 which are provided withprovisions for securing the bucket support 30 to parallel conveyorchains (shown in dotted lines in FIG. 7) which comprise the bucketconveyor 12 (see also FIG. 5 of the '392 patent). Each of the individualbuckets 14 is centered on the chains at a desired pitch of, for example,twelve inches. Bucket portion 15 is rotatably coupled to bucket support30 via a suitable bearing 36 (see FIGS. 14-15). In this way, bucketportion 15 is capable of rotating relative to bucket support 30 andtherefore relative to bucket conveyor 12.

The bucket 14 further includes a rotational limit mechanism that limitsthe range of rotation of the bucket portion 15 relative to the bucketsupport 30 between a first position wherein the transverse slot 20 issubstantially perpendicular to the machine direction MD of the buckets14 on bucket conveyor 12, and a second position wherein the transverseslot 20 is substantially parallel to the machine direction MD of thebuckets 14 on bucket conveyor 12. To this end, the bucket support 30includes an arcuate slot 38 adjacent a rear edge of bucket support 30and is symmetric about a centerline 40 (FIG. 2) parallel to the machinedirection. Details of the apparatus rotationally mounting the bucket andlimiting that rotation are vest seen in FIGS. 2-5A.

The bucket 14 further includes a V-shaped actuating lever 42 positionedon the underside of the bucket support 30. Lever 42 includes an aperture44 for rotationally supporting the lever 42 at the pivot axis 45 of thebucket portion 15. When lever 42 is rotated relative to bucket support30, bucket portion 15 also rotates with lever 42 and relative to bucketsupport 30. The V-shaped lever 42 further includes a second aperture 46at the end of one leg having a length such that the aperture 46 alignswith the slot 38 in bucket support 30. Preferably, in this embodiment,bucket portion 15 is provided with a boss 92 depending from channelfloor 26 (FIG. 5A). Boss 92 defines a shoulder 94 bottoming out on arm42, boss 92 extending through and captured in slot 38.

A cam follower 48 depends from pin 50 extending upwardly into and fixedin boss 92. A lower reduced diameter portion 93 of boss 92 is capturedin aperture 46 of arm 42 and cooperates with bucket conveyor 12 torotate the bucket portion 15 between the first and second positions, asexplained in more detail below.

Pin 50 of cam follower 48 projects into the boss 92 captured in arcuateslot 38. An outer cam bearing surface 52 projects below bucket support30 for applying a force to rotate the bucket portion 15 when urged by acam. The boss 92 and arcuate slot 38 cooperate to limit movement of thebucket portion 15 relative to bucket support 30. In particular, when thebucket portion 15 is in the first position, i.e., the transverse channel20 is substantially perpendicular to the machine direction of thebuckets 14 along bucket conveyor 12, the boss 92 engages or approaches afirst end 54 of arcuate slot 38. In a similar manner, when the bucketportion 15 is in the second position, i.e., the transverse channel 20 issubstantially parallel to the machine direction of the buckets 14 alongbucket conveyor 12, the boss 92 engages or approaches a second end 56 ofarcuate slot 38. Looking from a top plan view of the bucket 14, thebucket portion 15 moves from the first position to the second positionthrough a counter clockwise rotation of the bucket portion 15 and fromthe second position to the first position through a clockwise rotationof the bucket portion 15.

In addition to the limited rotation of the bucket portion 15 relative tobucket support 30 noted above, the bucket portion 15 may be biasedrelative to bucket support 30 toward, for instance, the first position.To this end, bucket 14 includes a biasing member, such as coil spring58. One end of coil spring 58 is coupled to bucket support 30 and theother end of coil spring 58 is coupled to the second leg of the V-shapedactuating lever 42. For instance, the second leg may include a suitableaperture 60 for coupling an end of the coil spring 58. In theconfiguration shown in the figures, the coil spring 58 applies arestoring force that resists movement of the bucket portion 15 away fromthe first position. In this way, the first position is a defaultposition such that without the application of a suitable force, thetransverse channel 20 will be substantially perpendicular to the machinedirection of the buckets 14 along bucket conveyor 12. Upon applicationof a sufficient cam force that overcomes the restoring force of the coilspring 58, the bucket portion 15 will rotate to the second position.While the biasing member is described herein as a coil spring, those ofordinary skill in the art will recognize that other biasing members maybe used to bias the buckets 14 in a desired orientation. For example, abungee cord or other elastic members may be used as a biasing member.

The buckets 14 cooperate with bucket conveyor 12 to selectively rotatethe bucket portion 15 between the first and second positions, as neededfor packaging a clip in a flat carton. As shown in FIG. 1 and FIG. 7 ofthe present application, the bucket conveyor 12 includes an active path70 and a return path 72. Along the active path 70, the tissue clips areloaded into the buckets 14 and are delivered to and packaged in theappropriate cartons. The return path 72 returns the buckets 14 to thebeginning of the active path 70 so that the handling apparatus 10 mayrun as a continuous-type system.

As shown in FIG. 6, the handling apparatus 10 includes a first camsurface 74 adapted to engage bearing surface 52 on cam follower 48. Thefirst cam surface 74 is configured such that as the bearing surface 52engages first cam surface 74, the actuating lever 42, and thus thebucket portion 15, is rotated relative to bucket support 30 from thefirst position with the channel transverse to the machine direction, tothe second position with the channel extending in the machine direction.First cam surface 74 may be positioned along bucket conveyor 12 when thetissue clip is being placed in the channel 20 of bucket portion 15 andends (i.e., is in the first position) prior to rotation of the clip andbucket for pushing the clip into the flat carton as previouslydescribed.

The handling apparatus 10 further optionally includes a second camsurface (not shown) on the return path 72 adapted to engage bearingsurface 52 on cam follower 48. In a similar manner, the second camsurface is configured such that as the bearing surface 52 engages thesecond cam surface, the actuating lever 42, and thus the bucket portion15, is positively rotated relative to the bucket support 30 from thesecond position to the first position. The second cam surface may bepositioned such that the bucket portion 15 is in the first positionprior to the tissue clips being positioned in the buckets 14 forboutique packaging.

As recognized by those of ordinary skill in the art, because the bucket14 is spring biased toward the first position, a cam surface along theentire travel path (active and return paths) of the bucket conveyor 12is not required. Due to the spring, once the buckets are in the firstposition, there is no need to have any cam surface to keep the buckets14 in the first position. However, the spring biasing also requires thatwhen it is desired to have the buckets 14 in the second position, thebearing surface 52 must engage a cam surface to maintain the bucket 14in the second position against the spring bias. Otherwise, the bucket 14would return to or remain in the first position due to the action of thespring. Thus as described above, a cam extends along the travel path ofthe buckets preferably only where it is desired to have the buckets inthe second position.

Those of ordinary skill in the art will recognize many alternativedesigns that are within the scope of the invention. For instance, thebiasing of the buckets in a preferred orientation, such as by use of thecoil spring 58, may be eliminated and a cam surface may extend theentire travel path of the buckets to accomplish the rotation of thebuckets between the first and second positions. In yet another design,the coil spring 58 may be eliminated and the buckets may include aspring-loaded detent associated with bucket portion 15 and two recessesassociated with bucket support 30 such that when the detent is engagedwith one of the recesses, the bucket is in the first position and whenthe detent is engaged with the other recess, the bucket is in the secondposition. Because the detent is spring loaded, only a sufficient forceacting on the bucket will rotate the bucket between the first and secondpositions. Additionally, when the bucket reaches the first and secondposition, there is no longer a need to apply a force to keep the bucketin a respective position. Thus, a cam surface does not have to extendalong the travel path for the entire time a bucket is in a certainorientation, as is the case for the embodiment described above. In thisdesign, a cam surface must be provided only when rotating between thefirst and second positions. Once the buckets are in the first or secondposition, a cam surface does not need to be provided as the springbiasing maintains the bucket in the desired orientation. Those ofordinary skill in the should also recognize that instead of a biasingmember to bias the bucket in the first position, a frictional fit mayexist between the pin 50 and the arcuate slot 38 so as to prevent anyundesired rotation of the bucket portion 15 relative to the bucketsupport 30 unless a sufficient force acts upon the bearing surface 52.

Operation of the handling apparatus 10 of this first embodiment will nowbe described. When it is desired to package the clips in a boutiquecarton, the buckets 14 are in the default, spring-biased first positionso that when a clip is positioned in the bucket 14, the clip spans thetransverse channel 20 as shown in FIG. 8A of the present application.The handling apparatus 10 is configured such that the buckets do notrequire any rotation of the clip in order to be packaged in the boutiquecarton, as described in more detail below. When it is desired to packagethe clips in a flat carton, however, the handling apparatus 10 must beconfigured to rotate the buckets 14 for receipt of the clips in channel20. Specifically and as noted above and in the '392 patent, it is mostdesirable to insert the clips endwise into flat cartons. Since the clipsare initially moved lengthwise in a downstream direction, however, it isnecessary to turn the clips 90 degrees so that they can be pushedtransversely out of the buckets in an endwise direction at the cartonerto load the flat cartons.

In order to accommodate this reorientation of the clips, a cam ispositioned along the bucket conveyor 12. Note that the cam may be addedas a changeover part or may be automated, such as with a pneumaticcylinder, to be properly positioned along bucket conveyor 12. Thebuckets 14 from the return path 72 engage the cam surface to rotate thebuckets 14 from the first position to the second position thereby havingthe transverse slot substantially parallel to the machine direction. Thebuckets 14 enter the active path 70 in this orientation and the tissueclips are loaded into the channels 20 of buckets 14 while in the secondposition. More particularly, the clips are loaded in buckets 14 so as tobe located within the channel 20 as shown in FIG. 8B of the presentapplication. After loading the clips in the buckets 14, the buckets 14disengage from the first cam surface 74. The spring bias rotates thebuckets 14 from the second position back to the first position. In thefirst position, the buckets 14 are oriented so that the clips in thetransverse channel 20 may be pushed endwise into the flat boxestransversely to the machine direction MD. After the clips are pushedfrom the buckets 14, the buckets are carried back along the return path72 to repeat the process.

Alternately, the bucket rotation is fully cam controlled by one or morecams.

The details of further packaging the clips in the boutique or flat boxesin the present invention are similar to that disclosed in the '392patent. In particular, as shown in FIGS. 9 and 10 of the '392 patent, acartoner includes a carton feeder, such as flat carton feeder FCF, forfeeding cartons onto a carton conveyor, the lugs of which areillustrated in FIGS. 9 and 10 of the '392 patent. As shown in FIG. 9 ofthat patent, a lug set engages erected flat cartons and moves them inthe downstream direction or machine direction. FIG. 9 of the '392 patentwill be described in this connection as illustrating the loading of theflat cartons with flat clips.

It will be appreciated that the cartoner also includes a transfer guidebucket conveyor having a plurality of transfer guide buckets. Thistransfer guide bucket conveyor is elongated in the machine direction andis interposed between the bucket conveyor and carton conveyor. Theconstruction of these transfer guide buckets is perhaps best seen inFIGS. 11, 11A and 11B of the '392 patent. Each transfer guide bucket hastwo opposed sidewalls which converge toward a discharge end from a widerreceiving end. Each of the guide buckets is mounted on two bracketscomprising the guide of the transfer guide bucket conveyor.

It will be appreciated that the transfer guide bucket conveyor asdisposed in the cartoner apparatus has only a limited operational run,as diagrammatically indicated in FIG. 3 of the '392 patent. Thistransfer guide bucket conveyor is disposed between the carton conveyoron the one side and the bucket conveyor on the other, so that clips,which are pushed from the buckets on the bucket conveyor, are movedtransversely through the guide buckets and into the cartons. In thisregard, it will be appreciated that the bucket channels are indexed andaligned with the transfer guide buckets and that the floors of thebuckets are in preferably the same plane as the floors of the transferguide bucket.

It will also be appreciated that the carton conveyor is provided in astandard or other desirable pitch such as twelve inches, however, itwill be appreciated that that pitch is defined by the lug sets. In anyevent, the bottom panel of the carton is disposed in about the same planand level as the floors of the transfer guide bucket and floor of thechannel of the buckets.

It will also be appreciated that the lug sets are on a similar pitchwith respect to each other, but that the distances between the lug setsmay vary, one to accommodate one particular width of a flat carton, forexample, and the other to accommodate the particular leading to trailingedge width of a boutique carton.

Accordingly, it will be appreciated that the bucket conveyor and thetransfer guide bucket conveyor are driven by drives which are controlledby independent servo drives with respect to the carton conveyor so thatthe appropriate phase alignment can be made when the machine isselectively switched from handling flat clips to boutique configuredclips.

Also, it will be appreciated that the loading of the clips into thecartons as shown in FIG. 9 of the '392 patent is accomplished by aconventional barrel loader having disposed on the ends of its pushers aU-shaped pusher. This pusher moves in a load direction to push the clipsfrom the floors of the channels through the transfer guide buckets,across their floors and into the cartons as illustrated in FIG. 9 of the'392 patent.

Thereafter, the barrel loader withdraws the pushers and the filledcartons are moved downstream for flap gluing, closing, and otherfinishing steps and discharge.

It will be appreciated that the clips are preferably compressed as theyenter the cartoner and are prepped for transport into the cartons. Flatconfiners or tampers are shown in this regard in the drawings of the'392 patent. For example, as shown in FIG. 9A of the '392 patent, aconfiner or tamp which may be mounted on an overhead carousel, forexample, descends via means of a cam driven track, for example, onto theclip, confining and compressing it in the channel.

This confiner may be elongated so that it extends along the full lengthof the clip lying transversely across the bucket. This confiner may alsoextend into or over the guide bucket as illustrated in FIG. 9B of the'392 patent, however, the confiner stops short in a transverse directionfrom the cartons. Thereafter, the confiners are lifted upwardly andaway, where they are moved through a return run and back toward an entryend of the cartoner.

Accordingly, as shown in FIG. 9A of the '392 patent, a confiner is moveddownwardly and which also continues to move in machine direction MD tocompress and confine the flat clip before and while it is being pushedwith the U-shaped pusher which does not interfere with the confinertransversely through the transfer guide bucket conveyor and into thecarton.

FIG. 9B of the '392 patent illustrates the continuing influence of theconfiner on the clip as it is pushed through the guide bucket and intothe carton.

Turning now to FIG. 10 of the '392 patent, it will be appreciated thatthis figure illustrates the packaging of a clip in a boutique carton orcontainer by first configuring the clip into a boutique shaped clip. InFIG. 10 of the '392 patent, it will be appreciated that a boutiquecarton feeder (BCF) has fed cartons onto the carton conveyor, thecartons being driven by the sets of carton conveying lugs at anappropriate pitch, and that the transfer guide bucket conveyor and thebucket conveyor has been phased by means of an appropriate servo driveinto appropriate registry with the cartons, all of which move downstreamand in a machine direction. Of course, it would be possible to provide aline drive machine, where the various phases are mechanically adjusted,however, the servo drive mechanisms for the various conveyors have beenfound to easily produce the phase registries that are required betweenthe components.

As shown in FIG. 10 of the '392 patent, the clip lies or spans acrossand over the channel and is supported by the rear and forward floor ofthe buckets. An elongated confiner or tamp, which has been substitutedfor the tamp used for flat cartons, is utilized to initiate and hold theclip in a U-shaped configuration partially at least down into channel.The confiner is not as wide in the machine direction as the confiner forthe flat carton and, when moved downwardly as illustrated in FIG. 10A ofthe '392 patent, pushes the clip downwardly into the channel of thebucket, so that the clip takes on a U-shaped configuration. This shapemay be more steeply inclined than as shown in FIG. 10A of the '392patent when the tamp compresses the bight of the clip.

As the side of the clip is engaged by the U-shaped pusher, the clip ispushed transversely out of the channel in a load direction into thetransfer guide buckets, the floors of which are preferably co-planarwith the floors of the bucket channels.

The confiners or tamps are elongated so they extend over the transferguide bucket and the confiners are carried on the horizontally movingcarousel described above, for example, with the confiners being raisedand lowered by an appropriate cam track, just as the confiners withrespect to FIG. 9 of the '392 patent. The confiners extend laterally ortransversely in a load direction into the area of the transfer guidebuckets and thus hold and maintain the clips in a U-shapedconfiguration, somewhat pressing the bight or intermediate portion ofthe clip into the channel and into the respective guide buckets as theclip is pushed.

The inwardly tapered walls of the transfer guide buckets serve tofurther confine and shape the boutique clips into the appropriate finalconfiguration for loading into the cartons as illustrated in FIG. 10 ofthe '392 patent as the buckets, the cartons and the guide buckets movefrom right to left as shown in this figure.

The pushers are mounted on and actuated by a barrel loader of anyconventional design, such that the pushers are moved in a load directionas shown in FIG. 10 of the '392 patent, transversely of the buckets andthe transfer guide buckets to push the clips into the boutique cartonsin a bent or U-shaped configuration.

Accordingly, it will be appreciated that the clips are urged downwardlyand at least partially into the channels to provide and accommodatetheir boutique configuration for loading into the cartons. Thereafter,the barrel loader withdraws the pusher and the confiners are raised,both to operate through return runs for further engagement, as themachine continues in operation.

Alternate Embodiment

In another embodiment of the invention, and referring to FIGS. 9-15, abucket 80 having a flat floor surface 82, comprising a product supportsurface, is provided. This product supporting bucket may have manyvaried floor configurations, either preferably flat or in any othershape, not limited to having a transverse, product receiving channel. Asshown in these Figures, the bucket floor 82 of this embodiment comprisesa relatively flat product receiving surface.

Except for the channel-shaped buckets 14 of the prior embodiment, andany further description noted below, the remaining structural elementsof this embodiment, together with the turning operation of the bucket80, are similar to those for that bucket 14 described above, withsimilar parts designated by similar numbers together with a suffix “a”thereon in FIGS. 9-15.

Products are deposited on bucket 80 and floor 82 thereof. Pre- orpost-bucket rotation is generated, both to receive and/or turn productsthereon to a desired orientation for processing or packaging. Thebuckets 80 can be provided with a plurality of features to facilitate orenhance product reception or orientation initially or through theprocess and where desired, but this embodiment is not limited to anyparticular bucket floor or product receiving surface.

With further attention to the structural details of the secondembodiment, it will be appreciated that a pin 84 is secured by nut 86 asa fixed pivot pin for rotation of bucket 80. Pin 84 is fixed againstrotation to plate 30 a. Bearing 36 a has an outer race (see FIGS. 14,15) preferably pressed into bucket 80 and an inner race preferablypressed about pin 84. A spacer bearing 88 is secured between bucket 80and plate 30 a, while bushing 90 serves to position arm 42 a about pin84 and turns about axis 45 a, allowing rotation of arm 42 a with respectto plate 30 a when follower 48 a is driven by a cam to rotate bucket 80.

In this embodiment (FIG. 15A), as well as in the first embodiment, aboss 92 (with like numbers being used) extends downwardly from bucket 80and defines a shoulder 94 facilitating connection of bucket 80 to arm 42a, as well as providing a receptor for pin 50 a. In this embodiment,boss 92 extends into slot 38 a (38) and moves therein. Alternately, theboss 92 could be foreshortened so pin 50 a would have a diameter closerto the width of slot 38 a and be captured therein.

Moreover, a boss 96 extends downwardly from bucket 80 into a circularrecess 98 in plate 30 a to facilitate rotational position of bucket 80on plate 30 a (see FIGS. 14, 15). Similar structure can be used in thefirst embodiment as well.

Bucket 80 differs from bucket 14 and instead of a channel, has arelatively flat floor 82. Bucket 80 preferably has leading and trailingwalls 100, 102 defining edges of floor 82, but could be otherwiseconfigured.

Slot 104 accommodates spring 58 a.

Accordingly, bucket 80 is rotatable about axis 45 a when driven by arm42 a and follower 52 a as the bucket is moved along a conveyor path. Inone position, leading and trailing walls 100, 102 are transverse to theconveyed machine direction. When the bucket 80 is in another rotatedposition, walls 100, 102 are parallel to the machine direction.

Products on bucket 80, bucket floor 82, are thus received thereon andare transferred and/or turned as desired for processing, packaging orthe like.

Tissue clips and other products can be processed, conveyed, oriented andtransferred in this second embodiment as desired, and with the sameadvantages as the previously described embodiment.

It should be appreciated that with all embodiments disclosed herein, theproducts, including but not limited to tissue clips, can be introducedonto the buckets from a variety of approach angles, such as parallel toor transversely to the bucket conveyor machine flow direction, or fromabove the buckets from any direction. The buckets are positioned to adesired rotational orientation for receiving the products, then can berotated, where desired, to rotate the product for further processing orpackaging. Preferably tissue clips are fed end-wise, with the narrowerend loading, from all the approach directions. Bucket rotation forreceiving and transferring the clips for desired packaging facilitate avariety of packaging configurations as will be appreciated.

Additionally, it will be appreciated that a variety of mechanisms ordevices in place of the described actuating arm and cam follower couldbe used to rotate the buckets. For example only, the buckets could berotated by electromagnetic, pneumatic, hydraulic or other forms ofdevices sufficient to rotate the buckets.

It will be appreciated that in the past, rotatable product supportplates have been used to orient products for translation in a conveyor.Such a prior device is shown, for example, in U.S. Pat. No. 6,435,332.The structure of the components of that device, however, are quitedifferent from that of both the first and second embodiments of thisinvention, however, as are readily ascertainable from these descriptionsand the claims herein.

And finally, for purposes of this application, a variety of any suitableexpedients can be used for rotating the buckets, i.e. product receivingmembers between first and second positions. These expedients or meansfor rotating include the cam and cam follower structures disclosed inthe drawings. They also include other forms of cams and cam followers aswell as other devices such as electronic, magnetic or pneumatic driverstructures, solenoids or the like and any device capable of selectivelyturning the buckets or members to positions ad described herein.

Operating modes of the invention are variable.

It will thus be appreciated this invention contemplates at least twobucket embodiments and is capable of receiving, transferring andorienting clips of tissue in a variety of methods or modes, includingthose discussed below:

1. First Embodiment

Boutique: Flat clips are fed in an MD direction, narrow end leading,onto a bucket (first position) with clips spanning a transverse bucketchannel. Clips are pushed from above downwardly into the channel into a“U”-shape for transverse loading into boutique cartons.

2. First Embodiment

Flat: Clips are fed in an MD direction, narrow end leading, towardbuckets which have been rotated (second position) so their bottomchannels extend also in an MD direction. The clips are deposited intothe channels and the buckets are then turned so the channel isperpendicular to the MD direction from where the flat clips are pushedin a direction transversely to the MD direction into flat cartons.

3. First Embodiment

Boutique—Side Feed: flat clips are fed, narrow end leading, in adirection perpendicular to machine direction MD and to buckets (secondposition) having a transverse channel. The clips span the channel, thebuckets are turned so the channels are oriented perpendicular to the MDdirection and packaging proceeds as in Mode 1 above.

4. First Embodiment

Flat—Side Feed: flat clips are fed, narrow end leading, in a directionperpendicular to direction MD. The clips are deposited into thetransverse channels of buckets (first position) and transfer continueswith clips being pushed transversely into flat cartons.

5. Second Embodiment

Boutique: flat clips are fed in an MD direction, narrow end leading,onto flat bottom buckets, are tamped intermediately to initiate a“U”-shaped configuration, and are pushed transversely into boutiquecartons.

6. Second Embodiment

Flat: flat clips are fed in an MD direction, narrow end leading, ontoflat bottom buckets in one position. The buckets are turned so the clipsare re-oriented with broad side leading and the clips are pushedtransversely, narrow end leading, into flat cartons.

7. Second Embodiment

Boutique—Side Feed: flat clips are fed, narrow end leading, in adirection perpendicular to a direction MD onto flat bottom buckets. Thebuckets are turned so the clips are re-oriented, narrow end leading, ina direction MD. Packaging proceeds as in Mode 5 above.

8. Second Embodiment

Flat—Side Feed: flat clips are fed, narrow end leading, in a directionperpendicular to a direction MD. From there, the clips can be pushedtransversely, narrow end leading, into flat cartons.

Other modes of operation will be appreciated, and the invention thusprovides a single transfer apparatus having multiple modes of flat andboutique tissue packaging.

While the present invention has been illustrated by a description ofvarious preferred embodiments and while these embodiments have beendescribed in some detail, it is not the intention of the Applicant torestrict or in any way limit the scope of the appended claims to suchdetail. For example, while the above description of the invention wasdirected to the packaging of tissue clips, those of ordinary skill inthe art will recognize that the invention may be used in the packagingof nearly any item where it is desirable to change the orientation ofthe item. Such a change in orientation may be desirable to mate amanufacturer's production line with various packaging machines. Thevarious features of the invention may be used alone or in numerouscombinations depending on the needs and preferences of the user. Thus,additional advantages and modifications will readily appear to thoseskilled in the art and without departing from the scope of thisinvention and applicant intends to be bound only by the claims appendedhereto.

What is claimed is:
 1. A method of transferring elongated tissue clipsfrom an infeed location to a downstream discharge location andselectively manipulating said clips into configurations suitable forselective insertion into one of flat packages and boutique packages atdifferent times on the same apparatus, comprising: at said infeedlocation placing flat elongated tissue clips on a rotatable carrierhaving a transverse channel therein, said clips spanning the channelwhen clips are to be packaged in a boutique package, said clipspositioned within the channel when the clips are to be packaged in aflat package; moving said carrier to a downstream discharge location;when said clips are to be packaged in a boutique package, pushing aportion of said clips into the channel to form a U-shaped clip slidingthe clips along said channel and inserting them into a boutique package;and when other clips are to be packaged in a flat package, rotating thecarrier from one position at said infeed location to a rotated positionat said discharge location and sliding clips from said channel into aflat package.
 2. In a handling apparatus having a bucket conveyor with aplurality of buckets, said bucket conveyor defining and moveable in amachine direction, each bucket having a floor with a channel formedtherein and being rotatable between a first position wherein the channelis substantially perpendicular to the machine direction and a secondposition wherein the channel is substantially parallel to the machinedirection, the buckets normally positioned in the first position; amethod of handling tissue clips selectively for configuration forpackaging into flat or boutique cartons, the method comprising: when theclips are to be packaged in boutique cartons: depositing a tissue clipin the bucket at an infeed location so as to span the channel; movingthe buckets toward a downstream discharge location; pushing a portion ofthe clips into the channel to form a U-shaped clips; sliding theU-shaped clip from said channel into a boutique package without rotatingsaid bucket; and when the clips are to be packaged in flat cartons;depositing clips into said channel at said infeed station with thebucket in said second position; the bucket to said discharge location;rotating said bucket to said first position while moving to thedischarge location with the channel extending perpendicular to themachine direction sliding the flat clips from the channel endwise into aflat carton.
 3. In apparatus for selectively packaging tissue clipshaving narrow ends, in either flat or boutique configurations, whereinsaid apparatus comprises a bucket conveyor having a plurality ofrotatable buckets moving in a first direction and rotatably mounted onrespective bucket supports, the method comprising: feeding flat tissueclips, narrow end leading, onto said buckets; and thereafter moving saidbuckets to a discharge location and selectively rotating said bucketswith said clips thereon with respect to said supports to position saidclips for one of said flat or boutique packaging configurations.
 4. Amethod as in claim 3 including the step of turning said buckets to afirst rotatable position for receiving flat clips to be packaged inboutique configuration, and forming said clip into a “U”-shape.
 5. Amethod as in claim 4 wherein said bucket defines a transverse channel insaid floor, said method including introducing said clips to said bucketin an orientation spanning said channel.
 6. A method as in claim 5including forming said clips in a “U” shape in said channel and pushingthe clip from said channel without any turning of the bucket after clipsare introduced thereto.
 7. A method as in claim 3 including transferringreceived clips and pushing said clips from said buckets without turningsaid bucket for packaging said clips in a flat configuration.
 8. Amethod as in claim 7 wherein said bucket comprises a floor having atransverse channel therein, said method including feeding said clips,narrow end leading, into said channel for packing in a flatconfiguration.
 9. An apparatus for transferring elongated tissue clipsfrom an infeed location in a downstream direction to a dischargelocation for packaging in selectively different clip configurations, amethod including the steps of: infeeding tissue clips into a series ofconveyor buckets after selectively rotationally orienting said bucketsto receive said clips in a desired orientation with respect to saidbuckets at said infeed location; transferring said clips in a saiddownstream direction to said discharge location and selectivelycontrolling a rotational position of said buckets to one of a rotated ornon-rotated orientation at said discharge location.